U.S. patent application number 12/718356 was filed with the patent office on 2010-06-24 for fischer-tropsch synthesis using microchannel technology and novel catalyst and microchannel reacotr.
Invention is credited to Michael D. Briscoe, Chunshe Cao, Ya-Huei Chin, Francis P. Daly, Nathan Gano, Jianli Hu, Charles Kibby, Xiaohong Shari Li, Terry Mazanec, Anna Lee Tonkovich, Dave VanderWiel, Yong Wang.
Application Number | 20100160463 12/718356 |
Document ID | / |
Family ID | 34795632 |
Filed Date | 2010-06-24 |
United States Patent
Application |
20100160463 |
Kind Code |
A1 |
Wang; Yong ; et al. |
June 24, 2010 |
FISCHER-TROPSCH SYNTHESIS USING MICROCHANNEL TECHNOLOGY AND NOVEL
CATALYST AND MICROCHANNEL REACOTR
Abstract
The disclosed invention relates to a process for converting a
reactant composition comprising H.sub.2 and CO to a product
comprising at least one aliphatic hydrocarbon having at least about
5 carbon atoms, the process comprising: flowing the reactant
composition through a microchannel reactor in contact with a
Fischer-Tropsch catalyst to convert the reactant composition to the
product, the microchannel reactor comprising a plurality of process
microchannels containing the catalyst; transferring heat from the
process microchannels to a heat exchanger; and removing the product
from the microchannel reactor; the process producing at least about
0.5 gram of aliphatic hydrocarbon having at least about 5 carbon
atoms per gram of catalyst per hour; the selectivity to methane in
the product being less than about 25%. The disclosed invention also
relates to a supported catalyst comprising Co, and a microchannel
reactor comprising at least one process microchannel and at least
one adjacent heat exchange zone.
Inventors: |
Wang; Yong; (Richland,
WA) ; Tonkovich; Anna Lee; (Marysville, OH) ;
Mazanec; Terry; (Solon, OH) ; Daly; Francis P.;
(Delaware, OH) ; VanderWiel; Dave; (Brecksville,
OH) ; Hu; Jianli; (Kennewick, WA) ; Cao;
Chunshe; (Kennewick, WA) ; Kibby; Charles;
(Benicia, CA) ; Li; Xiaohong Shari; (Richland,
WA) ; Briscoe; Michael D.; (Katy, TX) ; Gano;
Nathan; (Dublin, OH) ; Chin; Ya-Huei;
(Richland, WA) |
Correspondence
Address: |
Neil A. DuChez;RENNER, OTTO, BOISSELLE & SKLAR, P.L.L
19th Floor, 1621 Euclid Avenue
Cleveland
OH
44115
US
|
Family ID: |
34795632 |
Appl. No.: |
12/718356 |
Filed: |
March 5, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11484069 |
Jul 11, 2006 |
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12718356 |
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10766297 |
Jan 28, 2004 |
7084180 |
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11484069 |
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Current U.S.
Class: |
518/712 ;
422/211 |
Current CPC
Class: |
C10G 2300/4018 20130101;
C10G 2/341 20130101; B01J 2219/0086 20130101; C10G 2400/04
20130101; B01J 2219/00835 20130101; B01J 2219/00826 20130101; B01J
21/04 20130101; B01J 2219/00844 20130101; B01J 19/0093 20130101;
B01J 37/0205 20130101; B01J 2219/00873 20130101; C10G 2/332
20130101; B01J 2219/00831 20130101; B01J 23/75 20130101; C10G
2300/4025 20130101; C10G 2400/10 20130101; Y02P 20/582 20151101;
B01J 23/8913 20130101; B01J 35/1042 20130101; B01J 35/1038
20130101; B01J 2219/00822 20130101; B01J 2219/00824 20130101; B01J
2219/00783 20130101; C10G 2300/301 20130101; B01J 23/8896 20130101;
B01J 35/0066 20130101; C10G 2300/70 20130101; B01J 35/1019
20130101 |
Class at
Publication: |
518/712 ;
422/211 |
International
Class: |
C07C 1/04 20060101
C07C001/04; B01J 8/02 20060101 B01J008/02 |
Claims
1. A microchannel reactor comprising at least one microchannel, the
at least one microchannel comprising at least one catalyst, the
catalyst comprising a composition represented by the formula
CoM.sup.1.sub.aM.sup.2.sub.bO.sub.x wherein M.sup.1 is Fe, Ni, Ru,
Re, Os, or a mixture of two or more thereof; M.sup.2 is Li, B, Na,
K, Rb, Cs, Mg, Ca, Sr, Ba, Sc, Y, La, Ac, Ti, Zr, La, Ac, Ce or Th,
or a mixture of two or more thereof; a is a number in the range of
zero to about 0.5; b is a number in the range of zero to about 0.5;
and x is the number of oxygens needed to fulfill the valency
requirements of the elements present.
2. The microchannel reactor of claim 1 wherein the catalyst
comprises Co supported on alumina, the Co loading being at least
about 5% by weight.
3. The microchannel reactor of claim 1 wherein the catalyst
comprises Co supported on alumina, the Co loading being at least
about 25%.
4. The microchannel reactor of claim 1 wherein the catalyst
comprises Co supported on alumina, the Co dispersion being at least
about 3%.
5. The microchannel reactor of claim 1 wherein the catalyst is in
the form of particulate solids.
6. The microchannel reactor of claim 1 wherein the catalyst is
coated on interior walls of a microchannel, grown on interior walls
of a microchannel, or coated in situ on a fin structure.
7. The microchannel reactor of claim 1 wherein the catalyst is
supported by a support structure made of a material comprising an
alloy comprising Ni, Cr and Fe, or an alloy comprising Fe, Cr, Al
and Y.
8. The microchannel reactor of claim 1 wherein the catalyst is
supported on a support structure having a flow-by configuration, a
flow-through configuration, or a serpentine configuration.
9. The microchannel reactor of claim 1 wherein the catalyst is
supported on a support structure having the configuration of a
foam, felt, wad, fin, or a combination of two or more thereof.
10. The microchannel reactor of claim 1 wherein the catalyst is
supported on a support structure having a flow-by configuration
with an adjacent gap, a foam configuration with an adjacent gap, a
fin structure with gaps, a washcoat on a substrate, or a gauze
configuration with a gap for flow.
11. The microchannel reactor of claim 1 wherein the catalyst is
supported on a support structure in the form of a fin assembly
comprising at least one fin.
12. The microchannel reactor of claim 11 wherein the fin assembly
comprises a plurality of parallel spaced fins.
13. The microchannel reactor of claim 11 wherein the fin has an
exterior surface and a porous material overlies at least part of
the exterior surface of the fin, the catalyst being supported by
the porous material.
14. The microchannel reactor of claim 13 wherein the porous
material comprises a coating, fibers, foam or felt.
15. The microchannel reactor of claim 11 wherein the fin has an
exterior surface and a plurality fibers or protrusions extend from
at least part of the exterior surface of the fin, the catalyst
being supported by the protrusions.
16. The microchannel reactor of claim 11 wherein the fin has an
exterior surface and the catalyst is: washcoated on at least part
of the exterior surface of the fin; grown on at least part of the
exterior surface of the fin from solution; or deposited on at least
part of the exterior surface of the fin using vapor deposition.
17. The microchannel reactor of claim 11 wherein the fin assembly
comprises a plurality of parallel spaced fins, at least one of the
fins having a length that is different than the length of the other
fins.
18. The microchannel reactor of claim 11 wherein the fin assembly
comprises a plurality of parallel spaced fins, at least one of the
fins having a height that is different than the height of the other
fins.
19. The microchannel reactor of claim 11 wherein the fin has a
cross section having the shape of a square, a rectangle, or a
trapezoid.
20. The microchannel reactor of claim 11 wherein the fin is made of
a material comprising: steel; aluminum; titanium; iron; nickel;
platinum; rhodium; copper; chromium; brass; an alloy of any of the
foregoing metals; a polymer; ceramics; glass; a composite
comprising polymer and fiberglass; quartz; silicon; or a
combination of two or more thereof.
21. The microchannel reactor of claim 1 wherein the catalyst
comprises Co and a support, the catalyst being made by the process
comprising: (A) impregnating the support with a composition
comprising Co to provide an intermediate catalytic product; (B)
calcining the intermediate catalytic product formed in (A); (C)
impregnating the calcined intermediate product formed in (B) with a
composition comprising Co to provide another intermediate catalytic
product; and (D) calcining the another intermediate catalytic
product formed in (C) to form the catalyst, the catalyst having a
Co loading of at least about 25% by weight.
22. A process for conducting a Fischer-Tropsch reaction in a
microchannel reactor, the microchannel reactor comprising a
plurality of process microchannels and a plurality of heat exchange
channels, the heat exchange channels extending lengthwise at right
angles relative to the lengthwise direction of the process
microchannels, the process comprising: flowing reactants comprising
CO and H.sub.2 in the process microchannels in contact with a
Fischer-Tropsch catalyst to form a reaction product comprising one
or more aliphatic hydrocarbons, the catalyst comprising cobalt
supported on an alumina support and being in the form of
particulate solids, the cobalt loading being at least about 25% by
weight; exchanging heat between the process microchannels and a
heat exchange fluid in the heat exchange channels, the heat
exchange fluid undergoing a phase change in the heat exchange
channels.
23. The process of claim 22 wherein the reactants enter the process
microchannels and the product exits the process microchannels, the
temperature of the reactants entering the process microchannels
being within about 200.degree. C. of the temperature of the product
exiting the process microchannels.
24. The process of claim 22 wherein the mole ratio of H.sub.2 to CO
is in the range of about 0.8 to about 10.
25. The process of claim 22 wherein the reactants further comprise
H.sub.2O, CO.sub.2, a hydrocarbon of 1 to about 4 carbon atoms, or
a mixture of two or more thereof.
26. The process of claim 22 wherein the heat exchange fluid
undergoes partial boiling in the heat exchange channels.
27. The process of claim 22 wherein the reactants and product flow
in the process microchannels in a first direction, and the heat
exchange fluid flows in the heat exchange channels in a second
direction, the second direction being cross current relative to the
first direction.
28. The process of claim 22 wherein the heat exchange fluid
comprises air, steam, water, carbon dioxide, gaseous nitrogen, a
gaseous hydrocarbon or a liquid hydrocarbon.
29. The process of claim 22 wherein the heat exchange fluid
comprises water, the water undergoing partial boiling in the heat
exchange channels.
30. The process of claim 22 wherein the catalyst further comprises
Re, Ru or a mixture thereof.
31. The process of claim 22 wherein the process microchannels have
a bulk flow path comprising about 5% to about 95% of the cross
sections of such process microchannels.
32. The process of claim 22 wherein the contact time of the
reactants and/or product with the catalyst is up to about 2000
milliseconds.
33. The process of claim 22 wherein the temperature of the
reactants entering the process microchannels is in the range of
about 150.degree. C. to about 270.degree. C.
34. The process of claim 22 wherein the pressure within the process
microchannels is at least about 5 atmospheres.
35. The process of claim 22 wherein the space velocity for the flow
of the reactants and product in the process microchannels is at
least about 1000 hr..sup.-1
36. The process of claim 22 wherein the pressure drop for the flow
of the reactants and product in the process microchannels is up to
about 10 atmospheres per meter of length of the process
microchannels.
37. The process of claim 22 wherein the heat exchange fluid flows
in the heat exchange channels, the pressure drop for the heat
exchange fluid flowing in the heat exchange channels being up to
about 10 atmospheres per meter of length of the heat exchange
channels.
38. The process of claim 22 wherein the conversion of CO is at
least about 50%, the selectivity to methane in the product is about
25% or less, and the yield of product is at least about 35%.
39. The process of claim 22 wherein the catalyst comprises
particulate solids with a particle size in the range of about 1 to
about 1000 .mu.m.
40. The process of claim 22 wherein the product comprises
hydrocarbons boiling at a temperature at or below about 350.degree.
C. at atmospheric pressure.
41. The process of claim 22 wherein the product comprises
hydrocarbons boiling at or above a temperature of about 350.degree.
C. at atmospheric pressure.
42. The process of claim 22 wherein the product comprises a middle
distillate.
43. The process of claim 22 wherein the product comprises at least
one olefin.
44. The process of claim 22 wherein the product comprises a normal
paraffin, isoparaffin, or mixture thereof.
45. The process of claim 22 wherein the product is further
processed using hydrocracking, hydroisomerizing or dewaxing.
46. The process of claim 22 wherein the product is further
processed to form a lubricating base oil or a diesel fuel.
47. The process of claim 22 wherein the product flows out of the
microchannel reactor and subsequent to the product flowing out of
the microchannel reactor a regenerating fluid flows through the
process microchannels in contact with the catalyst, the residence
time for the regenerating fluid in the process microchannels being
from about 0.01 to about 1000 seconds.
48. The process of claim 22 wherein each process microchannel has
an internal dimension of up to about 10 mm.
49. The process of claim 22 wherein each heat exchange channel has
an internal dimension of up to about 10 mm.
50. The process of claim 22 wherein the process microchannels and
heat exchange channels are made of a material comprising: aluminum;
titanium; nickel; copper; an alloy of any of the foregoing metals;
steel; monel; inconel; brass; a polymer; ceramics; glass; a
composite comprising polymer and fiberglass; quartz; silicon; or a
combination of two or more thereof.
51. The process of claim 22 wherein the process microchannels and
heat exchange channels are made of stainless steel.
52. The process of claim 22 wherein the microchannel reactor
comprises a microchannel reactor core, a reactant header and a
product footer.
53. The process of claim 52 wherein the microchannel reactor
further comprises a heat exchange header and a heat exchange
footer.
54. The process of claim 52 wherein the process microchannels and
the heat exchange channels are positioned in the microchannel
reactor core.
55. The process of claim 52 wherein the microchannel reactor core
comprises layers of the process microchannels and layers of the
heat exchange channels aligned one above another or side by
side.
56. The process of claim 22 wherein each process microchannel has a
cross section having the shape of a square, rectangle, circle or
semi-circle.
57. The process of claim 22 wherein each process microchannel has a
cross section having the shape of a rectangle.
58. The process of claim 22 wherein each process microchannel has a
width and a length, the width tapering from a relatively small
dimension to a relatively large dimension over the length of the
process microchannel.
59. The process of claim 22 wherein each process microchannel has a
width in the range up to about 3 meters, and a length in the range
up to about 10 meters.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is a divisional of and claims
priority under 35 U.S.C. .sctn.120 to copending, commonly assigned
U.S. application Ser. No. 11/484,069, filed Jul. 11, 2006, which is
a divisional of U.S. application Ser. No. 10/766,297, filed Jan.
28, 2004 (now issued as U.S. Pat. No. 7,084,180 B2), the
disclosures of which are fully incorporated by reference
herein.
TECHNICAL FIELD
[0002] This invention relates to a Fischer-Tropsch synthesis
process using microchannel technology, and a novel catalyst and
microchannel reactor. The catalyst and reactor are useful in
Fischer-Tropsch synthesis processes.
BACKGROUND OF THE INVENTION
[0003] The Fischer-Tropsch synthesis reaction involves converting a
reactant composition comprising H.sub.2 and CO in the presence of a
catalyst to aliphatic hydrocarbon products. The reactant
composition may comprise the product stream from another reaction
process such as steam reforming (product stream
H.sub.2/CO.about.3), partial oxidation (product stream
H.sub.2/CO.about.2), autothermal reforming (product stream
H.sub.2/CO.about.2.5), CO.sub.2 reforming (H.sub.2/CO.about.1),
coal gasification (product stream H.sub.2/CO.about.1), and
combinations thereof. The aliphatic hydrocarbon products may range
from methane to paraffinic waxes of up to 100 carbon atoms or
more.
[0004] Conventional reactors such as tubular fixed bed reactors and
slurry reactors have various problems in heat and mass transfer
resulting in limitations of choice of process conditions for
Fischer-Tropsch synthesis reactions. Hot spots in the fixed bed
reactors significantly promote methane formation, reduce the heavy
hydrocarbon selectivity and deactivate the catalyst. On the other
hand, strong mass transfer resistance inherent in a catalyst
suspended in a slurry system generally reduces the effective
reaction rate and also causes difficulty in separation of catalysts
from the products. This invention provides a solution to these
problems.
[0005] This invention relates to a process for conducting a
Fischer-Tropsch synthesis reaction in a microchannel reactor
wherein the one-pass conversion of CO within the reactor is
enhanced and the selectivity to methane is reduced. With the
inventive process the tendency to form hot spots in the
microchannel reactor is reduced. This reduction in the tendency to
form hot spots is believed to be due, at least in part, to the fact
that the microchannel reactor provides enhanced heat transfer
characteristics and more precise control of temperatures and
residence times as compared to prior art processes wherein
microchannel reactors are not used. With this process, it is
possible to obtain relatively high levels of conversion of the CO
and high levels of selectivity to the desired product (e.g.,
hydrocarbons in the middle distillate range) as compared to such
prior art. A novel catalyst as well as a novel microchannel reactor
design are provided.
SUMMARY OF THE INVENTION
[0006] This invention relates to a process for converting a
reactant composition comprising H.sub.2 and CO to a product
comprising at least one aliphatic hydrocarbon having at least about
5 carbon atoms, the process comprising: flowing the reactant
composition through a microchannel reactor in contact with a
Fischer-Tropsch catalyst to convert the reactant composition to the
product, the microchannel reactor comprising a plurality of process
microchannels containing the catalyst; transferring heat from the
process microchannels to a heat exchanger; and removing the product
from the microchannel reactor; the process producing at least about
0.5 gram of aliphatic hydrocarbon having at least about 5 carbon
atoms per gram of catalyst per hour; the selectivity to methane in
the product being less than about 25%.
[0007] In one embodiment, the heat exchanger comprises a plurality
of heat exchange channels adjacent to the process microchannels. In
one embodiment, the heat exchange channels are microchannels.
[0008] In one embodiment, the invention relates to a catalyst
comprising Co supported on alumina, the loading of Co being at
least about 25% by weight, the Co dispersion being at least about
3%. This catalyst may further comprise Re, Ru or a mixture
thereof.
[0009] In one embodiment, the invention relates to a catalyst, the
catalyst comprising Co and a support, the catalyst being made by
the steps of: (A) impregnating the support with a composition
comprising Co to provide an intermediate catalytic product; (B)
calcining the intermediate catalytic product formed in step (A);
(C) impregnating the calcined intermediate product formed in step
(B) with a composition comprising Co to provide another
intermediate catalytic product; and (D) calcining the another
intermediate catalytic product formed in step (C) to form the
catalyst, the catalyst having a Co loading of at least about 25% by
weight. The composition comprising Co used in step (A) may be the
same as or it may be different than the composition comprising Co
used in step (C). The support may comprise alumina.
[0010] In one embodiment, the invention relates to a microchannel
reactor, comprising: at least one process microchannel, the process
microchannel having an entrance and an exit; and at least one heat
exchange zone adjacent to the process microchannel, the heat
exchange zone comprising a plurality of heat exchange channels, the
heat exchange channels extending lengthwise at right angles
relative to the lengthwise direction of the process microchannel;
the heat exchange zone extending lengthwise in the same direction
as the process microchannel and being positioned near the process
microchannel entrance; the length of the heat exchange zone being
less than the length of the process microchannel; the width of the
process microchannel at or near the process microchannel exit being
greater than the width of the process microchannel at or near the
process microchannel entrance. In one embodiment, the at least one
heat exchange zone comprises a first heat exchange zone and a
second heat exchange zone, the length of the second heat exchange
zone being less than the length of the first heat exchange
zone.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] In the annexed drawings, like parts and features have like
designations.
[0012] FIG. 1 is a schematic illustration of a microchannel that
may be used with the inventive process.
[0013] FIG. 2 is a schematic flow sheet illustrating the inventive
Fischer-Tropsch synthesis process in a particular form wherein a
reactant composition comprising CO and H.sub.2 flows through a
microchannel reactor in contact with a Fischer-Tropsch catalyst and
reacts to form a product comprising at least one aliphatic
hydrocarbon.
[0014] FIG. 3 is a schematic illustration of a layer of process
microchannels and a layer of heat exchange microchannels that may
be used in the microchannel reactor core of the microchannel
reactor illustrated in FIG. 2.
[0015] FIG. 4 is a schematic illustration of a process microchannel
and an adjacent heat exchange zone that may be used in the
microchannel reactor core of the microchannel reactor illustrated
in FIG. 2, the heat exchange zone containing a plurality of heat
exchange channels extending lengthwise at right angles relative to
the lengthwise direction of the process microchannel, the flow of
heat exchange fluid through the heat exchange channels being
cross-current relative to the flow of reactant composition and
product through the process microchannel.
[0016] FIG. 5 is a schematic illustration of a process microchannel
and an adjacent heat exchange channel that may be used in the
microchannel reactor core of the microchannel reactor illustrated
in FIG. 2, the flow of heat exchange fluid through the heat
exchange channel being counter-current relative to the flow of
reactant composition and product through the process
microchannel.
[0017] FIG. 6 is a schematic illustration of a process microchannel
and an adjacent heat exchange zone that may be used in the
microchannel reactor core of the microchannel reactor illustrated
in FIG. 2, the heat exchange zone containing a plurality of heat
exchange channels extending lengthwise at right angles relative to
the lengthwise direction of the process microchannel, the heat
exchange zone extending lengthwise in the same direction as the
process microchannel and being positioned at or near the process
microchannel entrance, the length of the heat exchange zone being
less than the length of the process microchannel.
[0018] FIG. 7 is a schematic illustration of a process microchannel
and first and second adjacent heat exchange zones that may be used
in the microchannel reactor core of the microchannel reactor
illustrated in FIG. 2, each of the heat exchange zones containing a
plurality of heat exchange channels extending lengthwise at right
angles relative to the lengthwise direction of the process
microchannel, the heat exchange zone extending lengthwise in the
same direction as the process microchannel and being positioned at
or near the process microchannel entrance, the length of the first
heat exchange zone being less than the length of the process
microchannel, the length of the second heat exchange zone being
less than the length of the first heat exchange zone.
[0019] FIG. 8 is a schematic illustration of a process microchannel
that may be used with the inventive process, the process
microchannel containing a catalyst having a flow-by
configuration.
[0020] FIG. 9 is a schematic illustration of a process microchannel
that may be used with the inventive process, the process
microchannel containing a catalyst having a flow-through
configuration.
[0021] FIG. 10 is a schematic illustration of a process
microchannel that may be used in the inventive process, the process
microchannel containing a fin assembly comprising a plurality of
fins, a catalyst being supported by the fins.
[0022] FIG. 11 illustrates an alternate embodiment of the process
microchannel and fin assembly illustrated in FIG. 10.
[0023] FIG. 12 illustrates another alternate embodiment of the
process microchannel and fin assembly illustrated in FIG. 10.
[0024] FIG. 13 is a plot of pore volume and surface area versus
cobalt loading obtained in Example 1.
[0025] FIGS. 14-17 are plots showing the results of the
Fischer-Tropsch synthesis reactions conducted in Example 3.
[0026] FIG. 18 is a plot showing the differences in Fischer-Tropsch
activity and selectivity for catalysts made in Example 4 with and
without intercalcinations.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The term "microchannel" refers to a channel having at least
one internal dimension of height or width of up to about 10
millimeters (mm), and in one embodiment up to about 5 mm, and in
one embodiment up to about 2 mm, and in one embodiment up to about
1 mm. The flow of fluid through the microchannel may proceed along
the length of the microchannel normal to the height and width of
the microchannel. An example of a microchannel that may be used
with the inventive process as a process microchannel and/or a heat
exchange microchannel is illustrated in FIG. 1. The microchannel 10
illustrated in FIG. 1 has a height (h), width (w) and length (l).
Fluid flows through the microchannel 10 along the length of the
microchannel in the direction indicated by arrows 12 and 14. The
height (h) or width (w) of the microchannel may be in the range of
about 0.05 to about 10 mm, and in one embodiment about 0.05 to
about 5 mm, and in one embodiment about 0.05 to about 2 mm, and in
one embodiment about 0.05 to about 1.5 mm, and in one embodiment
about 0.05 to about 1 mm, and in one embodiment about 0.05 to about
0.75 mm, and in one embodiment about 0.05 to about 0.5 mm. The
other dimension of height or width may be of any dimension, for
example, up to about 3 meters, and in one embodiment about 0.01 to
about 3 meters, and in one embodiment about 0.1 to about 3 meters.
The length (l) of the microchannel may be of any dimension, for
example, up to about 10 meters, and in one embodiment about 0.2 to
about 10 meters, and in one embodiment from about 0.2 to about 6
meters, and in one embodiment from 0.2 to about 3 meters. Although
the microchannel 10 illustrated in FIG. 1 has a cross section that
is rectangular, it is to be understood that the microchannel may
have a cross section having any shape, for example, a square,
circle, semi-circle, trapezoid, etc. The shape and/or size of the
cross section of the microchannel may vary over its length. For
example, the height or width may taper from a relatively large
dimension to a relatively small dimension, or vice versa, over the
length of the microchannel.
[0028] The term "adjacent" when referring to the position of one
channel relative to the position of another channel means directly
adjacent such that a wall separates the two channels. This wall may
vary in thickness. However, "adjacent" channels are not separated
by an intervening channel that would interfere with heat transfer
between the channels. In one embodiment, one channel may be
adjacent to another channel over only part of the dimension of the
another channel. For example, a process microchannel may be longer
than and extend beyond one or more adjacent heat exchange
channels.
[0029] The term "fluid" refers to a gas, a liquid, or a gas or a
liquid containing dispersed solids or liquid droplets.
[0030] The term "contact time" refers to the volume of the reaction
zone within the microchannel reactor divided by the volumetric feed
flow rate of the reactant composition at a temperature of 0.degree.
C. and a pressure of one atmosphere.
[0031] The term "residence time" refers to the internal volume of a
space (e.g., the reaction zone within a microchannel reactor)
occupied by a fluid flowing through the space divided by the
average volumetric flowrate for the fluid flowing through the space
at the temperature and pressure being used.
[0032] The term "reaction zone" refers to the space within the
process microchannels wherein the reactants contact the
catalyst.
[0033] The term "conversion of CO" refers to the CO mole change
between the reactant composition and product divided by the moles
of CO in the reactant composition.
[0034] The term "selectivity to methane" refers to the moles of
methane in the product divided by the moles of methane plus two
times the number of moles of C.sub.2 hydrocarbons in the product,
plus three times the number of moles of C.sub.3 hydrocarbons in the
product, plus four times the number of moles of C.sub.4
hydrocarbons in the product, etc., until all of the moles of
hydrocarbons in the product have been included.
[0035] The term "one-pass conversion of CO" refers to the
conversion of CO after one pass through the microchannel reactor
employed with the inventive process.
[0036] The term "yield of product" refers to conversion of CO
multiplied by selectivity to the indicated product(s).
[0037] The term "metal dispersion" refers to the percent of
catalytically active metal atoms and promoter atoms on the surface
of the catalyst as compared to the total number of metal atoms in
the catalyst as measured by hydrogen chemisorption which is
described in "Heterogeneous Catalysis in Industrial Practice,"
2.sup.nd ed., Charles N. Satterfield, p. 139, McGraw Hill (1996),
which is incorporated herein by reference.
[0038] In the expression "about 0.5 gram of aliphatic hydrocarbon
having at least about 5 carbon atoms per gram of catalyst per hour"
the weight or number of grams of catalyst refers to the total
weight of the catalyst consisting of the catalytic metal (e.g., Co)
or oxide thereof, optional co-catalyst (e.g., Re or Ru), and/or
promoter (e.g., Na, K, etc.) as well as the weight of any support
(e.g., alumina). However, if the catalyst is supported on an
engineered support structure such as a foam, felt, wad or fin, the
weight of such engineered support structure is not included in the
calculation of the weight or number of grams of catalyst.
Similarly, if the catalyst is adhered to the microchannel walls,
the weight of the microchannel walls is not included in the
calculation.
[0039] The term "Co loading" refers to the weight of the Co in the
catalyst divided by the total weight of the catalyst, that is, the
total weight of the Co plus any co-catalyst or promoter as well as
the support. If the catalyst is supported on an engineered support
structure such as a foam, felt, wad or fin, the weight of such
engineered support structure is not included in the calculation.
Similarly, if the catalyst is adhered to the microchannel walls,
the weight of the microchannel walls is not included in the
calculation.
[0040] Referring to FIG. 2, the process may be conducted using
microchannel reactor 100 which includes microchannel reactor core
102, reactant header 104, product footer 106, heat exchange header
108 and heat exchange footer 110. The microchannel reactor core 102
contains a plurality of process microchannels and a plurality of
heat exchange channels adjacent to the process microchannels. The
heat exchange channels may be microchannels. The process
microchannels and heat exchange channels may be aligned in layers,
one above the other, or side by side. A Fischer-Tropsch catalyst is
contained within the process microchannels. The process header 104
provides a passageway for fluid to flow into the process
microchannels with an even or substantially even distribution of
flow to the process microchannels. The process footer 106 provides
a passageway for fluid to flow from the process microchannels in a
rapid manner with a relatively high rate of flow. The reactant
composition flows into the microchannel reactor 100 through the
reactant header 104, as indicated by directional arrow 112. The
reactant composition may be preheated prior to entering the
reactant header 104. The reactant composition flows through the
process microchannels in the microchannel reactor core 102 in
contact with the catalyst and reacts to form the desired product.
In one embodiment, the flow of reactant composition and product
through the reactor core 102 is in a vertical direction, from the
top of the reactor core 102 to its bottom. The product, and in one
embodiment unreacted components from the reactant composition, flow
from the reactor core 102 through the product footer 106, and out
of product footer 106, as indicated by directional arrow 114.
Although an advantage of the inventive process is that a high level
of conversion of CO may be obtained with one pass through the
process microchannels, in one embodiment, unreacted components from
the reactant composition or a portion thereof may be recycled back
through the process microchannels in contact with the catalyst. The
unreacted components of the reactant composition being recycled
through the process microchannels may be recycled any number of
times, for example, one, two, three, four times, etc. A heat
exchange fluid flows into heat exchange header 108, as indicated by
directional arrow 116, and from heat exchange header 108 through
the heat exchange channels in microchannel reactor core 102 to heat
exchange footer 110, and out of heat exchange footer 110, as
indicated by directional arrow 118. The microchannel reactor 100 is
employed in conjunction with storage vessels, pumps, valves, flow
control devices, and the like, which are not shown in the drawings,
but would be apparent to those skilled in the art.
[0041] In one embodiment, the microchannel reactor core 102 may
contain layers of process microchannels and heat exchange
microchannels aligned side by side. An example of such
microchannels layers is illustrated in FIG. 3. Referring to FIG. 3,
process microchannel layers 130 and heat exchange microchannel
layers 150 are stacked side by side to provide repeating unit 170.
Microchannel layer 130 provides for the flow of reactant and
product. Microchannel layer 150 provides for the flow of heat
exchange fluid.
[0042] Microchannel layer 130 contains a plurality of microchannels
132 aligned in parallel, each process microchannel 132 extending in
a vertical direction along the length of microchannel layer 130
from end 134 to end 136, the process microchannels 132 extending
along the width of microchannel layer 130 from end 138 to end 140.
Bonding strips 142 and 144 are positioned at the ends 138 and 140,
respectively, of microchannel layer 130 to permit bonding of the
microchannel layer 130 to the next adjacent heat exchange layers
150. A catalyst is contained within the process microchannels 132.
The flow of reactant and product through the process microchannels
132 may be in the direction indicated by arrows 146 and 148. Each
of the process microchannels 132 may have a cross section having
any shape, for example, a square, rectangle, circle, semi-circle,
etc. The internal height of each process microchannel 132 may be
considered to be the vertical or horizontal distance or gap between
the microchannel layer 130 and the next adjacent heat exchange
layer 150. Each process microchannel 132 may have an internal
height of up to about 10 mm, and in one embodiment up to about 6
mm, and in one embodiment up to about 4 mm, and in one embodiment
up to about 2 mm. In one embodiment, the height may be in the range
of about 0.05 to about 10 mm, and in one embodiment about 0.05 to
about 6 mm, and in one embodiment about 0.05 to about 4 mm, and in
one embodiment about 0.05 to about 2 mm. The width of each of these
microchannels may be of any dimension, for example, up to about 3
meters, and in one embodiment about 0.01 to about 3 meters, and in
one embodiment about 0.1 to about 3 meters. The length of each
process microchannel 132 may be of any dimension, for example, up
to about 10 meters, and in one embodiment about 0.2 to about 10
meters, and in one embodiment from about 0.2 to about 6 meters, and
in one embodiment from 0.2 to about 3 meters.
[0043] Microchannel layer 150 contains a plurality of heat exchange
microchannels 152 aligned in parallel, each heat exchange
microchannel 152 extending horizontally along the width of
microchannel layer 150 from end 154 to end 156, the heat exchange
microchannels 152 extending along the length of microchannel layer
150 from end 158 to end 160 of microchannel layer 150. Bonding
strips 162 and 164 are positioned at ends 154 and 156,
respectively, of microchannel layer 150 to permit bonding of the
microchannel layer 150 to the next adjacent process microchannel
layers 130. The heat exchange fluid may flow through the heat
exchange microchannels 152 in the direction indicated by arrows 166
and 168. The flow of heat exchange fluid in the direction indicated
by arrows 166 and 168 is cross-current to the flow of reactant and
product flowing through process microchannels 132 as indicated by
arrows 146 and 148. Alternatively, the heat exchange microchannels
152 could be oriented to provide for flow of the heat exchange
fluid along the width of the microchannel layer 150 from end 158 to
end 160 or from end 160 to end 158. This would result in the flow
of heat exchange fluid in a direction that would be cocurrent or
counter-current to the flow of reactant and product through the
process microchannels 132. Each of the heat exchange microchannels
152 may have a cross section having any shape, for example, a
square, rectangle, circle, semi-circle, etc. The internal height of
each heat exchange microchannel 152 may be considered to be the
vertical or horizontal distance or gap between the heat exchange
microchannel layer 150 and the next adjacent microchannel layer
130. Each of the heat exchange microchannels 152 may have an
internal height of up to about 2 mm, and in one embodiment in the
range of about 0.05 to about 2 mm, and in one embodiment about 0.05
to about 1.5 mm. The width of each of these microchannels may be of
any dimension, for example, up to about 3 meters, and in one
embodiment from about 0.01 to about 3 meters, and in one embodiment
about 0.1 to about 3 meters. The length of each of the heat
exchange microchannels 152 may be of any dimension, for example, up
to about 10 meters, and in one embodiment from about 0.2 to about
10 meters, and in one embodiment from about 0.2 to about 6 meters,
and in one embodiment from 0.2 to about 3 meters.
[0044] Alternatively, the process microchannels and heat exchange
microchannels may be aligned as provided for in repeating unit
170a. Repeating unit 170a is illustrated in FIG. 4. Referring to
FIG. 4, process microchannel 132 is positioned adjacent to
microchannel layer 150 which contains heat exchange microchannels
152. A common wall 171 separates the process microchannel 132 from
the heat exchange microchannel layer 150. A catalyst 172 is packed
into the process microchannel 132. The reactant composition flows
into and through the packed bed of catalyst 172 in process
microchannel 132 in the direction indicated by directional arrow
146, contacts catalyst 172 and reacts to form the desired product.
The product, and in one embodiment unreacted components from the
reactant composition, exit the process microchannel 132 as
indicated by directional arrow 148. Heat exchange fluid flows
through the heat exchange microchannels 152 in a direction that is
cross-current to the flow of reactant composition and product
through the process microchannel 132.
[0045] Alternatively, the process microchannels and heat exchange
microchannels may be aligned as provided for in repeating unit
170b. Repeating unit 170b illustrated in FIG. 5 is identical to the
repeating unit 170a illustrated in FIG. 4 with the exception that
the microchannel layer 150 is rotated 90.degree. and the heat
exchange fluid flowing through the heat exchange microchannel 152
flows in the direction indicated by direction arrows 166a and 168a
which is countercurrent to the flow of reactant composition and
product through the process microchannel 132. Alternatively, the
heat exchange fluid could flow in the direction opposite to that
indicated by directional arrows 166a and 168a and thereby provide
for the flow of heat exchange fluid through the heat exchange
microchannel 152 in a direction that would be cocurrent relative to
the direction of reactant composition and product through the
process microchannel 132.
[0046] Alternatively, the process microchannels and heat exchange
microchannels may be aligned as provided for in repeating unit
170c. Repeating unit 170c is illustrated in FIG. 6. Referring to
FIG. 6, process microchannel 132a is positioned adjacent to heat
exchange zone 151. Heat exchange zone 151 contains a plurality of
heat exchange microchannels 152 aligned in parallel relative to one
another, each heat exchange microchannel 152 extending lengthwise
at a right angle relative to the lengthwise direction of the
process microchannel 132a. Heat exchange zone 151 is shorter in
length than process microchannel 132a. Heat exchange zone 151
extends lengthwise from or near the entrance 134a to process
microchannel 132a to a point along the length of the process
microchannel 132a short of the exit 136a to the process
microchannel 132a. In one embodiment, the length of heat exchange
zone 151 is up to about 100% of the length of process microchannel
132a, and in one embodiment the length of heat exchange zone 151 is
from about 5 to about 100% of the length of the process
microchannel 132a, and in one embodiment the length of the heat
exchange zone 151 is from about 5 to about 50% of the length of the
process microchannel 132a, and in one embodiment the length of the
heat exchange zone 151 is from about 50% to about 100% of the
length of the process microchannel 132a. The width of the process
microchannel 132a is expanded or extended in the area downstream of
the end 153 of the heat exchange zone 151. This arrangement
provides the advantage of heat exchange (i.e., cooling) at or near
the entrance 134a to the process microchannel 132a as well as to
parts of the process microchannel 132a downstream from the
entrance. A catalyst 172 is packed in the process microchannel
132a. The reactant composition flows into and through the packed
bed of catalyst 172 in process microchannel 132a in the direction
indicated by directional arrow 146, contacts catalyst 172 and
reacts to form the desired product. The product, and in one
embodiment unreacted components from the reactant composition, exit
the process microchannel 132a, as indicated by directional arrow
148. Heat exchange fluid flows through the heat exchange
microchannels 152 in a direction that is cross-current to the flow
of reactant composition and product through the process
microchannel 132a.
[0047] Alternatively, the process microchannels and heat exchange
microchannels may be aligned as provided for in repeating unit
170d. Repeating unit 170d, which is illustrated in FIG. 7, is
identical to the repeating unit 170c illustrated in FIG. 6 with the
exception that repeating unit 170d includes heat exchange zone 151a
adjacent to process microchannel 132a on the opposite side of the
process microchannel 132a from the heat exchange zone 151. Heat
exchange zone 151a contains a plurality of parallel heat exchange
microchannels 152a which are the same as or similar in size and
design to the heat exchange microchannels 152 discussed above. Heat
exchange zone 151a extends lengthwise from or near the entrance
134a to process microchannel 132a to a point along the length of
process microchannel 132a short of the end 153 of heat exchange
zone 151. The length of the heat exchange zone 151a may be shorter
than the length of the heat exchange zone 151. In one embodiment,
the length of the heat exchange zone 151a may be up to about 100%
of the length of the process microchannel 132a, and in one
embodiment the length of the heat exchange zone 151a is from about
5 to about 100% of the length of the process microchannel 132a, and
in one embodiment the length of the heat exchange zone 151a is from
about 5 to about 50% of the length of the process microchannel
132a, and in one embodiment the length of the heat exchange zone
151a is from about 50% to about 100% of the length of the process
microchannel 132a. The width of the process microchannel 132a is
expanded in the areas downstream of the ends 153 and 153a of the
heat exchange zones 151 and 151a, respectively. This arrangement
provides the advantage of heat exchange (i.e., cooling) at or near
the entrance 134a to the process microchannel 132a as well to parts
of the process microchannel 132a downstream from the entrance 134a.
The use of the two heat exchange zones 151 and 151a allows for a
relatively high level of heat exchange in the area of the process
microchannel 132a near its entrance, and a relatively moderate heat
exchange in the process microchannel downstream from about the end
153a of heat exchange zone 151a. Catalyst 172 is packed into the
process microchannel 132a. The reactant composition flows into and
through the packed bed of catalyst 172 in process microchannel 132a
in the direction indicated by directional arrow 146, contacts the
catalyst 172 and reacts to form the desired product. The product,
and in one embodiment unreacted components from the reactant
composition, exit the process microchannel 132a, as indicated by
directional arrow 148. Heat exchange fluid flows through the heat
exchange channels 151 and 151a in a direction which is
cross-current to the flow of reactant composition and product
through the process microchannel 132a.
[0048] The catalyst bed may be segregated into separate reaction
zones in the process microchannels in the direction of flow through
the process microchannels. In each reaction zone the length of one
or more adjacent heat exchange zone(s) may vary in their
dimensions. For example, in one embodiment, the length of the one
or more adjacent heat exchange zones may be less than about 50% of
the length of each reaction zone. Alternatively, the one or more
heat exchange zones may have lengths that are more than about 50%
of the length of each reaction zone up to about 100% of the length
of each reaction zone.
[0049] The number of microchannels in each of the microchannel
layers 130 and 150 may be any desired number, for example, one,
two, three, four, five, six, eight, ten, hundreds, thousands, tens
of thousands, hundreds of thousands, millions, etc. Similarly, the
number of repeating units 170 (or 170a through 170d) of
microchannel layers in the microchannel reactor core 102 may be any
desired number, for example, one, two, three, four, six, eight,
ten, hundreds, thousands, etc.
[0050] The microchannel reactor 100, including the microchannel
reactor core 102, may be constructed of any material that provides
sufficient strength, dimensional stability and heat transfer
characteristics for carrying out the inventive process. Examples of
suitable materials include steel (e.g., stainless steel, carbon
steel, and the like), aluminum, titanium, nickel, and alloys of any
of the foregoing metals, plastics (e.g., epoxy resins, UV cured
resins, thermosetting resins, and the like), monel, inconel,
ceramics, glass, composites, quartz, silicon, or a combination of
two or more thereof. The microchannel reactor may be fabricated
using known techniques including wire electrodischarge machining,
conventional machining, laser cutting, photochemical machining,
electrochemical machining, molding, water jet, stamping, etching
(for example, chemical, photochemical or plasma etching) and
combinations thereof. The microchannel reactor may be constructed
by forming layers or sheets with portions removed that allow flow
passage. A stack of sheets may be assembled via diffusion bonding,
laser welding, diffusion brazing, and similar methods to form an
integrated device. The microchannel reactor has appropriate
manifolds, valves, conduit lines, etc. to control flow of the
reactant composition and product, and flow of the heat exchange
fluid. These are not shown in the drawings, but can be readily
provided by those skilled in the art.
[0051] The reactant composition comprises a mixture of H.sub.2 and
CO. This mixture may be referred to as synthesis gas or syngas. The
molar ratio of H.sub.2 to CO may range from about 0.8 to about 10,
and in one embodiment about 0.8 to about 5, and in one embodiment
about 1 to about 3, and in one embodiment about 1.5 to about 3, and
in one embodiment about 1.8 to about 2.5, and in one embodiment
about 1.9 to about 2.2, and in one embodiment about 2.05 to about
2.10. The reactant composition may also contain CO.sub.2 and/or
H.sub.2O, as well as light hydrocarbons of 1 to about 4 carbon
atoms, and in one embodiment 1 to about 2 carbon atoms. The
reactant composition may contain from about 5 to about 45% by
volume CO, and in one embodiment about 5 to about 20% by volume CO;
and about 55 to about 95% by volume H.sub.2, and in one embodiment
about 80 to about 95% by volume H.sub.2. The concentration of
CO.sub.2 in the reactant composition may be up to about 60% by
volume, and in one embodiment about 5 to about 60% by volume, and
in one embodiment about 5 to about 40% by volume. The concentration
of H.sub.2O in the reactant composition may be up to about 80% by
volume, and in one embodiment about 5 to about 80% by volume, and
in one embodiment about 5 to about 50% by volume. The concentration
of light hydrocarbons in the reactant composition may be up to
about 80% by volume, and in one embodiment about 1 to about 80% by
volume, and in one embodiment about 1 to about 50% by volume. The
reactant composition may comprise recycled gaseous products formed
during the inventive process. The reactant composition may comprise
a stream (e.g., a gaseous stream) from another process such as a
steam reforming process (product stream with H.sub.2/CO mole ratio
of about 3), a partial oxidation process (product stream with
H.sub.2/CO mole ration of about 2), an autothermal reforming
process (product stream with H.sub.2/CO mole ratio of about 2.5), a
CO.sub.2 reforming process (product stream with H.sub.2/CO mole
ratio of about 1), a coal gassification process (product stream
with H.sub.2/CO mole ratio of about 1), and combinations
thereof.
[0052] The presence of contaminants such as sulfur, nitrogen,
halogen, selenium, phosphorus, arsenic, and the like, in the
reactant composition may be undesirable. Thus, in one embodiment of
the invention, the foregoing contaminants may be removed from the
reactant composition or have their concentrations reduced prior to
conducting the inventive process. Techniques for removing these
contaminants are well known to those of skill in the art. For
example, ZnO guardbeds may be used for removing sulfur impurities.
In one embodiment, the contaminant level in the reactant
composition may be at a level of up to about 5% by volume, and in
one embodiment up to about 1% by volume, and in one embodiment up
to about 0.1% by volume, and in one embodiment up to about 0.05% by
volume.
[0053] The heat exchange fluid may be any fluid. These include air,
steam, liquid water, gaseous nitrogen, other gases including inert
gases, carbon monoxide, molten salt, oils such as mineral oil, and
heat exchange fluids such as Dowtherm A and Therminol which are
available from Dow-Union Carbide.
[0054] The heat exchange fluid may comprise a stream of the
reactant composition. This can provide process pre-heat and
increase in overall thermal efficiency of the process.
[0055] In one embodiment, the heat exchange channels comprise
process channels wherein an endothermic process is conducted. These
heat exchange process channels may be microchannels. Examples of
endothermic processes that may be conducted in the heat exchange
channels include steam reforming and dehydrogenation reactions.
Steam reforming of an alcohol that occurs at a temperature in the
range of about 200.degree. C. to about 300.degree. C. is another
example of such an endothermic process. The incorporation of a
simultaneous endothermic reaction to provide an improved heat sink
may enable a typical heat flux of roughly an order of magnitude
above the convective cooling heat flux. The use of simultaneous
exothermic and endothermic reactions to exchange heat in a
microchannel reactor is disclosed in U.S. patent application Ser.
No. 10/222,196, filed Aug. 15, 2002, which is incorporated herein
by reference.
[0056] In one embodiment, the heat exchange fluid undergoes a
partial or full phase change as it flows through the heat exchange
channels. This phase change provides additional heat removal from
the process microchannels beyond that provided by convective
cooling. For a liquid heat exchange fluid being vaporized, the
additional heat being transferred from the process microchannels
would result from the latent heat of vaporization required by the
heat exchange fluid. An example of such a phase change would be an
oil or water that undergoes boiling. In one embodiment, about 50%
by weight of the heat exchange fluid is vaporized.
[0057] The heat flux for convective heat exchange in the
microchannel reactor may range from about 1 to about 25 watts per
square centimeter of surface area of the process microchannels
(W/cm.sup.2) in the microchannel reactor, and in one embodiment
from about 1 to about 10 W/cm.sup.2. The heat flux for phase change
or simultaneous endothermic reaction heat exchange may range from
about 1 to about 250 W/cm.sup.2, and in one embodiment from about 1
to about 100 W/cm.sup.2, and in one embodiment from about 1 to
about 50 W/cm.sup.2, and in one embodiment from about 1 to about 25
W/cm.sup.2, and in one embodiment from about 1 to about 10
W/cm.sup.2.
[0058] The cooling of the process microchannels during the
inventive process, in one embodiment, is advantageous for
controlling selectivity towards the main or desired product due to
the fact that such added cooling reduces or eliminates the
formation of undesired by-products from undesired parallel
reactions with higher activation energies. As a result of this
cooling, in one embodiment, the temperature of the reactant
composition at the entrance to the process microchannels may be
within about 200.degree. C., and in one embodiment within about
150.degree. C., and in one embodiment within about 100.degree. C.,
and in one embodiment within about 50.degree. C., and in one
embodiment within about 25.degree. C., and in one embodiment within
about 10.degree. C., of the temperature of the product (or mixture
of product and unreacted reactants) at the exit of the process
microchannels.
[0059] The catalyst may comprise any Fischer-Tropsch catalyst. The
catalyst comprises at least one catalytically active metal or oxide
thereof. In one embodiment, the catalyst further comprises a
catalyst support. In one embodiment, the catalyst further comprises
at least one promoter. The catalytically active metal may comprise
Co, Fe, Ni, Ru, Re, Os, or a combination of two or more thereof.
The support material may comprise alumina, zirconia, silica,
aluminum fluoride, fluorided alumina, bentonite, ceria, zinc oxide,
silica-alumina, silicon carbide, a molecular sieve, or a
combination of two or more thereof. The support material may
comprise a refractory oxide. The promoter may comprise a Group IA,
IIA, IIIB or IVB metal or oxide thereof, a lanthanide metal or
metal oxide, or an actinide metal or metal oxide. In one
embodiment, the promoter is Li, B, Na, K, Rb, Cs, Mg, Ca, Sr, Ba,
Sc, Y, La, Ac, Ti, Zr, La, Ac, Ce or Th, or an oxide thereof, or a
mixture of two or more thereof. Examples of catalysts that may be
used include those disclosed in U.S. Pat. Nos. 4,585,798;
5,036,032; 5,733,839; 6,075,062; 6,136,868; 6,262,131B1;
6,353,035B2; 6,368,997B2; 6,476,085B2; 6,451,864B1; 6,490,880B1;
6,537,945B2; 6,558,634B1; and U.S. Patent Publications
2002/0028853A1; 2002/0188031A1; and 2003/0105171A1; these patents
and patent publications being incorporated herein by reference for
their disclosures of Fischer-Tropsch catalysts and methods for
preparing such catalysts.
[0060] In one embodiment, the catalyst comprises Co, and optionally
a co-catalyst and/or promoter, supported on a support wherein the
Co loading is at least about 5% by weight, and in one embodiment at
least about 10% by weight, and in one embodiment at least about 15%
by weight, and in one embodiment at least about 20% by weight, and
in one embodiment at least about 25% by weight, and in one
embodiment at least about 28% by weight, and in one embodiment at
least about 30% by weight, and in one embodiment at least about 32%
by weight, and in one embodiment at least about 35% by weight, and
in one embodiment at least about 40% by weight. In one embodiment,
the Co loading may be from about 5 to about 50% by weight, and in
one embodiment about 10 to about 50% by weight, and in one
embodiment about 15 to about 50% by weight, and in one embodiment
about 20 to about 50% by weight, and in one embodiment about 25 to
about 50% by weight, and in one embodiment about 28 to about 50% by
weight, and in one embodiment about 30 to about 50% by weight, and
in one embodiment about 32 to about 50% by weight. The metal
dispersion for the catalytically active metal (i.e., Co, and
optionally co-catalyst and/or promoter) of the catalyst may range
from about 1 to about 30%, and in one embodiment about 2 to about
20%, and in one embodiment about 3 to about 20%. The co-catalyst
may be Fe, Ni, Ru, Re, Os, or an oxide thereof, or a mixture of two
or more thereof. The promoter may be a Group IA, IIA, IIIB or IVB
metal or oxide thereof, a lanthanide metal or metal oxide, or an
actinide metal or metal oxide. In one embodiment, the promoter is
Li, B, Na, K, Rb, Cs, Mg, Ca, Sr, Ba, Sc, Y, La, Ac, Ti, Zr, La,
Ac, Ce or Th, or an oxide thereof, or a mixture of two or more
thereof. The co-catalyst may be employed at a concentration of up
to about 10% by weight based on the total weight of the catalyst
(i.e., the weight of catalyst, co-catalyst, promoter and support),
and in one embodiment about 0.1 to about 5% by weight. The promoter
may be employed at a concentration of up to about 10% by weight
based on the total weight of the catalyst, and in one embodiment
about 0.1 to about 5% by weight.
[0061] In one embodiment, the catalyst may comprise Co supported by
alumina; the loading of Co being at least about 25% by weight, and
in one embodiment at least about 28% by weight, and in one
embodiment at least about 30% by weight, and in one embodiment at
least about 32% by weight; and the Co dispersion is at least about
3%, and in one embodiment at least about 5%, and in one embodiment
at least about 7%.
[0062] In one embodiment, the catalyst may comprise a composition
represented by the formula
CoM.sup.1.sub.aM.sup.2.sub.bO.sub.x
wherein: M.sup.1 is Fe, Ni, Ru, Re, Os or a mixture thereof, and in
one embodiment M.sup.1 is Ru or Re or a mixture thereof; M.sup.2 is
Li, B, Na, K, Rb, Cs, Mg, Ca, Sr, Ba, Sc, Y, La, Ac, Ti, Zr, La,
Ac, Ce or Th, or a mixture of two or more thereof; a is a number in
the range of zero to about 0.5, and in one embodiment zero to about
0.2; b is a number in the range of zero to about 0.5, and in one
embodiment zero to about 0.1; and x is the number of oxygens needed
to fulfill the valency requirements of the elements present.
[0063] In one embodiment, the catalyst used in the inventive
process may be made using multiple impregnation steps wherein
intercalcination steps are conducted between each impregnation
step. The use of such a procedure, at least in one embodiment,
allows for the formation of catalysts with levels of loading of
catalytic metal and optionally promoter that are higher than with
procedures wherein such intercalcination steps are not employed. In
one embodiment, a catalytic metal (e.g., Co) and optionally
co-catalyst (e.g., Re or Ru) and/or promoter is loaded on a support
(e.g., Al.sub.2O.sub.3) using the following sequence of steps: (A)
impregnating the support with a composition comprising a catalytic
metal and optionally a co-catalyst and/or promoter to provide an
intermediate catalytic product; (B) calcining the intermediate
catalytic product formed in step (A); (C) impregnating the calcined
intermediate product formed in (B) with another composition
comprising a catalytic metal and optionally a co-catalyst and/or
promoter, to provide another intermediate catalytic product; and
(D) calcining the another intermediate catalytic product formed in
step (C) to provide the desired catalyst product. The catalytic
metal and optional co-catalyst and/or promoter may be impregnated
on the support using an incipient wetness impregnation process.
Steps (C) and (D) may be repeated one or more additional times
until the desired loading of catalytic metal, and optional
co-catalyst and/or promoter, is achieved. The composition
comprising the catalytic metal may be a nitrate solution of the
metal, for example, a cobalt nitrate solution. The process may be
continued until the catalytic metal (i.e., Co) achieves a loading
level of about 20% by weight or more, and in one embodiment about
25% by weight or more, and in one embodiment about 28% by weight or
more, and in one embodiment about 30% by weight or more, and in one
embodiment about 32% by weight or more, and in one embodiment about
35% by weight or more, and in one embodiment about 37% by weight or
more, and in one embodiment about 40% by weight or more. Each of
the calcination steps may comprise heating the catalyst at a
temperature in the range of about 100.degree. C. to about
500.degree. C., and in one embodiment about 100.degree. C. to about
400.degree. C., and in one embodiment about 250 to about
350.degree. C. for about 0.5 to about 100 hours, and in one
embodiment about 0.5 to about 24 hours, and in one embodiment about
2 to about 3 hours. The temperature may be ramped to the
calcination temperature at a rate of about 1-20.degree. C./min. The
calcination steps may be preceded by drying steps wherein the
catalyst is dried at a temperature of about 75 to about 200.degree.
C., and in one embodiment about 75.degree. C. to about 150.degree.
C., for about 0.5 to about 100 hours, and in one embodiment about
0.5 to about 24 hours. In one embodiment, the catalyst may be dried
for about 12 hours at about 90.degree. C. and then at about
110-120.degree. C. for about 1-1.5 hours, the temperature being
ramped from 90.degree. C. to 110-120.degree. C. at a rate of about
0.5-1.degree. C./min.
[0064] The catalyst used in a microchannel reactor may have any
size and geometric configuration that fits within the process
microchannels. The catalyst may be in the form of particulate
solids (e.g., pellets, powder, fibers, and the like) having a
median particle diameter of about 1 to about 1000 .mu.m (microns),
and in one embodiment about 10 to about 500 .mu.m, and in one
embodiment about 25 to about 250 .mu.m. In one embodiment, the
catalyst is in the form of a fixed bed of particulate solids.
[0065] In one embodiment, the catalyst is in the form of a fixed
bed of particulate solids, the median particle diameter of the
catalyst particulate solids is relatively small, and the length of
each process microchannel is relatively short. The median particle
diameter may be in the range of about 1 to about 1000 .mu.m, and in
one embodiment about 10 to about 500 .mu.m, and the length of each
process microchannel may be in the range of up to about 500 cm, and
in one embodiment about 10 to about 500 cm, and in one embodiment
about 50 to about 300 cm.
[0066] The catalyst may be supported on a porous support structure
such as a foam, felt, wad or a combination thereof. The term "foam"
is used herein to refer to a structure with continuous walls
defining pores throughout the structure. The term "felt" is used
herein to refer to a structure of fibers with interstitial spaces
therebetween. The term "wad" is used herein to refer to a structure
of tangled strands, like steel wool. The catalyst may be supported
on a honeycomb structure.
[0067] The catalyst may be supported on a flow-by support structure
such as a felt with an adjacent gap, a foam with an adjacent gap, a
fin structure with gaps, a washcoat on any inserted substrate, or a
gauze that is parallel to the flow direction with a corresponding
gap for flow. An example of a flow-by structure is illustrated in
FIG. 8. In FIG. 8, the catalyst 300 is contained within process
microchannel 302. An open passage way 304 permits the flow of fluid
through the process microchannel 302 in contact with the catalyst
300 as indicated by arrows 306 and 308.
[0068] The catalyst may be supported on a flow-through support
structure such as a foam, wad, pellet, powder, or gauze. An example
of a flow-through structure is illustrated in FIG. 9. In FIG. 9,
the flow-through catalyst 310 is contained within process
microchannel 312 and the fluid flows through the catalyst 310 as
indicated by arrows 314 and 316.
[0069] The support structure for a flow-through catalyst may be
formed from a material comprising silica gel, foamed copper,
sintered stainless steel fiber, steel wool, alumina, poly(methyl
methacrylate), polysulfonate, poly(tetrafluoroethylene), iron,
nickel sponge, nylon, polyvinylidene difluoride, polypropylene,
polyethylene, polyethylene ethylketone, polyvinyl alcohol,
polyvinyl acetate, polyacrylate, polymethylmethacrylate,
polystyrene, polyphenylene sulfide, polysulfone, polybutylene, or a
combination of two or more thereof. In one embodiment, the support
structure may be made of a heat conducting material, such as a
metal, to enhance the transfer of heat away from the catalyst.
[0070] The catalyst may be directly washcoated on the interior
walls of the process microchannels, grown on the walls from
solution, or coated in situ on a fin structure. The catalyst may be
in the form of a single piece of porous contiguous material, or
many pieces in physical contact. In one embodiment, the catalyst
may be comprised of a contiguous material and has a contiguous
porosity such that molecules can diffuse through the catalyst. In
this embodiment, the fluids flow through the catalyst rather than
around it. In one embodiment, the cross-sectional area of the
catalyst occupies about 1 to about 99%, and in one embodiment about
10 to about 95% of the cross-sectional area of the process
microchannels. The catalyst may have a surface area, as measured by
BET, of greater than about 0.5 m.sup.2/g, and in one embodiment
greater than about 2 m.sup.2/g.
[0071] The catalyst may comprise a porous support, an interfacial
layer on the porous support, and a catalyst material on the
interfacial layer. The interfacial layer may be solution deposited
on the support or it may be deposited by chemical vapor deposition
or physical vapor deposition. In one embodiment the catalyst has a
porous support, a buffer layer, an interfacial layer, and a
catalyst material. Any of the foregoing layers may be continuous or
discontinuous as in the form of spots or dots, or in the form of a
layer with gaps or holes.
[0072] The porous support may have a porosity of at least about 5%
as measured by mercury porosimetry and an average pore size (sum of
pore diameters divided by number of pores) of about 1 to about 1000
.mu.m. The porous support may be a porous ceramic or a metal foam.
Other porous supports that may be used include carbides, nitrides,
and composite materials. The porous support may have a porosity of
about 30% to about 99%, and in one embodiment about 60% to about
98%. The porous support may be in the form of a foam, felt, wad, or
a combination thereof. The open cells of the metal foam may range
from about 20 pores per inch (ppi) to about 3000 ppi, and in one
embodiment about 20 to about 1000 ppi, and in one embodiment about
40 to about 120 ppi. The term "ppi" refers to the largest number of
pores per inch (in isotropic materials the direction of the
measurement is irrelevant; however, in anisotropic materials, the
measurement is done in the direction that maximizes pore
number).
[0073] The buffer layer, when present, may have a different
composition and/or density than both the porous support and the
interfacial layers, and in one embodiment has a coefficient of
thermal expansion that is intermediate the thermal expansion
coefficients of the porous support and the interfacial layer. The
buffer layer may be a metal oxide or metal carbide. The buffer
layer may be comprised of Al.sub.2O.sub.3, TiO.sub.2, SiO.sub.2,
ZrO.sub.2, or combination thereof. The Al.sub.2O.sub.3 may be
.alpha.-Al.sub.2O.sub.3, .gamma.-Al.sub.2O.sub.3 or a combination
thereof. .alpha.-Al.sub.2O.sub.3 provides the advantage of
excellent resistance to oxygen diffusion. The buffer layer may be
formed of two or more compositionally different sublayers. For
example, when the porous support is metal, for example a stainless
steel foam, a buffer layer formed of two compositionally different
sub-layers may be used. The first sublayer (in contact with the
porous support) may be TiO.sub.2. The second sublayer may be
.alpha.-Al.sub.2O.sub.3 which is placed upon the TiO.sub.2. In one
embodiment, the .alpha.-Al.sub.2O.sub.3 sublayer is a dense layer
that provides protection of the underlying metal surface. A less
dense, high surface area interfacial layer such as alumina may then
be deposited as support for a catalytically active layer.
[0074] The porous support may have a thermal coefficient of
expansion different from that of the interfacial layer. In such a
case a buffer layer may be needed to transition between the two
coefficients of thermal expansion. The thermal expansion
coefficient of the buffer layer can be tailored by controlling its
composition to obtain an expansion coefficient that is compatible
with the expansion coefficients of the porous support and
interfacial layers. The buffer layer should be free of openings and
pin holes to provide superior protection of the underlying support.
The buffer layer may be nonporous. The buffer layer may have a
thickness that is less than one half of the average pore size of
the porous support. The buffer layer may have a thickness of about
0.05 to about 10 .mu.m, and in one embodiment about 0.05 to about 5
.mu.m.
[0075] In one embodiment of the invention, adequate adhesion and
chemical stability may be obtained without a buffer layer. In this
embodiment the buffer layer may be omitted.
[0076] The interfacial layer may comprise nitrides, carbides,
sulfides, halides, metal oxides, carbon, or a combination thereof.
The interfacial layer provides high surface area and/or provides a
desirable catalyst-support interaction for supported catalysts. The
interfacial layer may be comprised of any material that is
conventionally used as a catalyst support. The interfacial layer
may be comprised of a metal oxide. Examples of metal oxides that
may be used include .gamma.-Al.sub.2O.sub.3, SiO.sub.2, ZrO.sub.2,
TiO.sub.2, tungsten oxide, magnesium oxide, vanadium oxide,
chromium oxide, manganese oxide, iron oxide, nickel oxide, cobalt
oxide, copper oxide, zinc oxide, molybdenum oxide, tin oxide,
calcium oxide, aluminum oxide, lanthanum series oxide(s),
zeolite(s) and combinations thereof. The interfacial layer may
serve as a catalytically active layer without any further
catalytically active material deposited thereon. Usually, however,
the interfacial layer is used in combination with a catalytically
active layer. The interfacial layer may also be formed of two or
more compositionally different sublayers. The interfacial layer may
have a thickness that is less than one half of the average pore
size of the porous support. The interfacial layer thickness may
range from about 0.5 to about 100 .mu.m, and in one embodiment from
about 1 to about 50 .mu.m. The interfacial layer may be either
crystalline or amorphous. The interfacial layer may have a BET
surface area of at least about 1 m.sup.2/g.
[0077] The catalyst may be deposited on the interfacial layer.
Alternatively, the catalyst material may be simultaneously
deposited with the interfacial layer. The catalyst layer may be
intimately dispersed on the interfacial layer. That the catalyst
layer is "dispersed on" or "deposited on" the interfacial layer
includes the conventional understanding that microscopic catalyst
particles are dispersed: on the support layer (i.e., interfacial
layer) surface, in crevices in the support layer, and in open pores
in the support layer.
[0078] The catalyst may be supported on an assembly of one or more
fins positioned within the process microchannels. Examples are
illustrated in FIGS. 10-12. Referring to FIG. 10, fin assembly 320
includes fins 322 which are mounted on fin support 324 which
overlies base wall 326 of process microchannel 328. The fins 322
project from the fin support 324 into the interior of the process
microchannel 328. The fins 322 extend to and may contact the
interior surface of upper wall 330 of process microchannel 328. Fin
channels 332 between the fins 322 provide passage ways for fluid to
flow through the process microchannel 328 parallel to its length.
Each of the fins 322 has an exterior surface on each of its sides,
this exterior surface provides a support base for the catalyst.
With the inventive process, the reactant composition flows through
the fin channels 332, contacts the catalyst supported on the
exterior surface of the fins 322, and reacts to form the product.
The fin assembly 320a illustrated in FIG. 11 is similar to the fin
assembly 320 illustrated in FIG. 10 except that the fins 322a do
not extend all the way to the interior surface of the upper wall
330 of the microchannel 328. The fin assembly 320b illustrated in
FIG. 12 is similar to the fin assembly 320 illustrated in FIG. 10
except that the fins 322b in the fin assembly 320b have cross
sectional shapes in the form of trapezoids. Each of the fins may
have a height ranging from about 0.02 mm up to the height of the
process microchannel 328, and in one embodiment from about 0.02 to
about 10 mm, and in one embodiment from about 0.02 to about 5 mm,
and in one embodiment from about 0.02 to about 2 mm. The width of
each fin may range from about 0.02 to about 5 mm, and in one
embodiment from about 0.02 to about 2 mm and in one embodiment
about 0.02 to about 1 mm. The length of each fin may be of any
length up to the length of the process microchannel 328, and in one
embodiment up to about 10 m, and in one embodiment about 0.5 to
about 10 m, and in one embodiment about 0.5 to about 6 m, and in
one embodiment about 0.5 to about 3 m. The gap between each of the
fins may be of any value and may range from about 0.02 to about 5
mm, and in one embodiment from about 0.02 to about 2 mm, and in one
embodiment from about 0.02 to about 1 mm. The number of fins in the
process microchannel 328 may range from about 1 to about 50 fins
per centimeter of width of the process microchannel 328, and in one
embodiment from about 1 to about 30 fins per centimeter, and in one
embodiment from about 1 to about 10 fins per centimeter, and in one
embodiment from about 1 to about 5 fins per centimeter, and in one
embodiment from about 1 to about 3 fins per centimeter. Each of the
fins may have a cross-section in the form of a rectangle or square
as illustrated in FIG. 10 or 11, or a trapezoid as illustrated in
FIG. 12. When viewed along its length, each fin may be straight,
tapered or have a serpentine configuration. The fin assembly may be
made of any material that provides sufficient strength, dimensional
stability and heat transfer characteristics to permit operation for
which the process microchannel is intended. These materials
include: steel (e.g., stainless steel, carbon steel, and the like);
monel; inconel; aluminum; titanium; nickel; platinum; rhodium;
copper; chromium; brass; alloys of any of the foregoing metals;
polymers (e.g., thermoset resins); ceramics; glass; composites
comprising one or more polymers (e.g., thermoset resins) and
fiberglass; quartz; silicon; or a combination of two or more
thereof. The fin assembly may be made of an Al.sub.2O.sub.3 forming
material such as an alloy comprising Fe, Cr, Al and Y, or a
Cr.sub.2O.sub.3 forming material such as an alloy of Ni, Cr and
Fe.
[0079] In one embodiment, the catalyst may be regenerated. This may
be done by flowing a regenerating fluid through the process
microchannels in contact with the catalyst. The regenerating fluid
may comprise hydrogen or a diluted hydrogen stream. The diluent may
comprise nitrogen, argon, helium, methane, carbon dioxide, steam,
or a mixture of two or more thereof. The regenerating fluid may
flow from the header 104 through the process microchannels and to
the footer 106, or in the opposite direction from the footer 106
through the process microchannels to the header 104. The
temperature of the regenerating fluid may be from about 50 to about
400.degree. C., and in one embodiment about 200 to about
350.degree. C. The pressure within the process microchannels during
this regeneration step may range from about 1 to about 40
atmospheres, and in one embodiment about 1 to about 20 atmospheres,
and in one embodiment about 1 to about 5 atmospheres. The residence
time for the regenerating fluid in the process microchannels may
range from about 0.01 to about 1000 seconds, and in one embodiment
about 0.1 second to about 100 seconds.
[0080] In one embodiment, the process microchannels may be
characterized by having a bulk flow path. The term "bulk flow path"
refers to an open path (contiguous bulk flow region) within the
process microchannels. A contiguous bulk flow region allows rapid
fluid flow through the microchannels without large pressure drops.
In one embodiment, the flow of fluid in the bulk flow region is
laminar. Bulk flow regions within each process microchannel may
have a cross-sectional area of about 0.05 to about 10,000 mm.sup.2,
and in one embodiment about 0.05 to about 5000 mm.sup.2, and in one
embodiment about 0.1 to about 2500 mm.sup.2. The bulk flow regions
may comprise from about 5% to about 95%, and in one embodiment
about 30% to about 80% of the cross-section of the process
microchannels.
[0081] The contact time of the reactants with the catalyst within
the process microchannels may range up to about 2000 milliseconds
(ms), and in one embodiment from about 10 ms to about 1000 ms, and
in one embodiment about 20 ms to about 500 ms. In one embodiment,
the contact time may range up to about 300 ms, and in one
embodiment from about 20 to about 300 ms, and in one embodiment
from about 50 to about 150 ms, and in one embodiment about 75 to
about 125 ms, and in one embodiment about 100 ms.
[0082] The space velocity (or gas hourly space velocity (GHSV)) for
the flow of the reactant composition and product through the
process microchannels may be at least about 1000 hr.sup.-1 (normal
liters of feed/hour/liter of volume within the process
microchannels) or at least about 800 ml feed/(g catalyst) (hr). The
space velocity may range from about 1000 to about 1,000,000
hr.sup.-1, or from about 800 to about 800,000 ml feed/(g catalyst)
(hr). In one embodiment, the space velocity may range from about
10,000 to about 100,000 hr.sup.-1, or about 8,000 to about 80,000
ml feed/(g catalyst) (hr).
[0083] The temperature of the reactant composition entering the
process microchannels may range from about 150.degree. C. to about
270.degree. C., and in one embodiment about 180.degree. C. to about
250.degree. C., and in one embodiment about 180.degree. C. to about
220.degree. C.
[0084] The temperature of the reactant composition and product
within the process microchannels may range from about 200.degree.
C. to about 300.degree. C., and in one embodiment from about
220.degree. C. to about 270.degree. C., and in one embodiment from
about 220.degree. C. to about 250.degree. C.
[0085] The temperature of the product exiting the process
microchannels may range from about 200.degree. C. to about
300.degree. C., and in one embodiment about 220.degree. C. to about
270.degree. C., and in one embodiment about 220.degree. C. to about
250.degree. C.
[0086] The pressure within the process microchannels may be at
least about 5 atmospheres, and in one embodiment at least about 10
atmospheres, and in one embodiment at least about 15 atmospheres,
and in one embodiment at least about 20 atmospheres, and in one
embodiment at least about 25 atmospheres, and in one embodiment at
least about 30 atmospheres. In one embodiment the pressure may
range from about 5 to about 50 atmospheres, and in one embodiment
from about 10 to about 50 atmospheres, and in one embodiment from
about 10 to about 30 atmospheres, and in one embodiment from about
10 to about 25 atmospheres, and in one embodiment from about 15 to
about 25 atmospheres.
[0087] The pressure drop of the reactants and/or products as they
flow through the process microchannels may range up to about 10
atmospheres per meter of length of the process microchannel
(atm/m), and in one embodiment up to about 5 atm/m, and in one
embodiment up to about 3 atm/m.
[0088] The reactant composition entering the process microchannels
is typically in the form of a vapor, while the product exiting the
process microchannels may be in the form of a vapor, a liquid, or a
mixture of vapor and liquid. The Reynolds Number for the flow of
vapor through the process microchannels may be in the range of
about 10 to about 4000, and in one embodiment about 100 to about
2000. The Reynolds Number for the flow of liquid through the
process microchannels may be about 10 to about 4000, and in one
embodiment about 100 to about 2000.
[0089] The heat exchange fluid entering the heat exchange channels
may be at a temperature of about 150.degree. C. to about
300.degree. C., and in one embodiment about 150.degree. C. to about
270.degree. C. The heat exchange fluid exiting the heat exchange
channels may be at a temperature in the range of about 220.degree.
C. to about 270.degree. C., and in one embodiment about 230.degree.
C. to about 250.degree. C. The residence time of the heat exchange
fluid in the heat exchange channels may range from about 50 to
about 5000 ms, and in one embodiment about 100 to about 1000 ms.
The pressure drop for the heat exchange fluid as it flows through
the heat exchange channels may range up to about 10 atm/m, and in
one embodiment from about 1 to about 10 atm/m, and in one
embodiment from about 2 to about 5 atm/m. The heat exchange fluid
may be in the form of a vapor, a liquid, or a mixture of vapor and
liquid. The Reynolds Number for the flow of vapor through the heat
exchange channels may be from about 10 to about 4000, and in one
embodiment about 100 to about 2000. The Reynolds Number for the
flow of liquid through heat exchange channels may be from about 10
to about 4000, and in one embodiment about 100 to about 2000.
[0090] The conversion of CO may be about 40% or higher per cycle,
and in one embodiment about 50% or higher, and in one embodiment
about 55% or higher, and in one embodiment about 60% or higher, and
in one embodiment about 65% or higher, and in one embodiment about
70% or higher. The term "cycle" is used herein to refer to a single
pass of the reactants through the process microchannels.
[0091] The selectivity to methane in the product may be about 25%
or less, and in one embodiment about 20% or less, and in one
embodiment about 15% or less, and in one embodiment about 12% or
less, and in one embodiment about 10% or less.
[0092] The yield of product may be about 25% or higher per cycle,
and in one embodiment about 30% or higher, and in one embodiment
about 40% or higher per cycle.
[0093] In one embodiment, the conversion of CO is at least about
50%, the selectivity to methane is about 15% or less, and the yield
of product is at least about 35% per cycle.
[0094] The product formed by the inventive process may comprise a
gaseous product fraction and a liquid product fraction. The gaseous
product fraction may include hydrocarbons boiling below about
350.degree. C. at atmospheric pressure (e.g., tail gases through
middle distillates). The liquid product fraction (the condensate
fraction) may include hydrocarbons boiling above about 350.degree.
C. (e.g., vacuum gas oil through heavy paraffins).
[0095] The product fraction boiling below about 350.degree. C. may
be separated into a tail gas fraction and a condensate fraction,
e.g., normal paraffins of about 5 to about 20 carbon atoms and
higher boiling hydrocarbons, using, for example, a high pressure
and/or lower temperature vapor-liquid separator, or low pressure
separators or a combination of separators. The fraction boiling
above about 350.degree. C. (the condensate fraction) may be
separated into a wax fraction boiling in the range of about
350.degree. C. to about 650.degree. C. after removing one or more
fractions boiling above about 650.degree. C. The wax fraction may
contain linear paraffins of about 20 to about 50 carbon atoms with
relatively small amounts of higher boiling branched paraffins. The
separation may be effected using fractional distillation.
[0096] The product formed by the inventive process may include
methane, wax and other heavy high molecular weight products. The
product may include olefins such as ethylene, normal and
iso-paraffins, and combinations thereof. These may include
hydrocarbons in the distillate fuel ranges, including the jet or
diesel fuel ranges.
[0097] Branching may be advantageous in a number of end-uses,
particularly when increased octane values and/or decreased pour
points are desired. The degree of isomerization may be greater than
about 1 mole of isoparaffin per mole of n-paraffin, and in one
embodiment about 3 moles of isoparaffin per mole of n-paraffin.
When used in a diesel fuel composition, the product may comprise a
hydrocarbon mixture having a cetane number of at least about
60.
[0098] Commercially, higher molecular weight products, for example
waxes, may either be isolated and used directly, or reacted to form
lower molecular weight products. For example, high molecular weight
products may be hydrocracked to provide lower molecular weight
products, increasing the yield of liquid combustible fuels.
Hydrocracking refers to a catalytic process, usually carried out in
the presence of free hydrogen, in which the cracking of the larger
hydrocarbon molecules is a primary purpose of the operation.
Catalysts used in carrying out hydrocracking operations are well
known in the art; see, for example, U.S. Pat. Nos. 4,347,121 and
4,810,357, which are incorporated herein by reference, for their
descriptions of hydrotreating, hydrocracking, and catalysts used in
each process. The product formed by the inventive process may be
further processed to form a lubricating base oil or diesel fuel.
For example, the product made by the inventive process may be
hydrocracked and then subjected to distillation and/or catalytic
isomerization to provide a lubricating base oil, diesel fuel, and
the like.
[0099] The hydrocarbon products made by the inventive process may
be hydroisomerized using the process disclosed in U.S. Pat. Nos.
6,103,099 or 6,180,575; hydrocracked and hydroisomerized using the
process disclosed in U.S. Pat. No. 4,943,672 or 6,096,940; dewaxed
using the process disclosed in U.S. Pat. No. 5,882,505; or
hydroisomerized and dewaxed using the process disclosed in U.S.
Pat. No. 6,013,171, 6,080,301 or 6,165,949. These patents are
incorporated herein by reference for their disclosures of processes
for treating Fischer-Tropsch synthesized hydrocarbons and the
resulting products made from such processes.
Example 1
[0100] A multiple impregnation process is used to form a Co/Re
catalyst supported on Al.sub.2O.sub.3. Separate batches of
impregnation solutions (with different concentrations) are used for
each impregnation. The composition of each impregnation solution is
as follows: Impregnation solution A contains 31.0% by weight cobalt
nitrate and 2.8% by weight perrhenic acid. Impregnation solution B
contains 29.8% by weight cobalt nitrate and 2.7% by weight
perrhenic acid. Impregnation solution C contains 38.7% by weight
cobalt nitrate and 3.5% by weight perrhenic acid. Impregnation
solution D contains 40.7% by weight cobalt nitrate and 3.6% by
weight perrhenic acid. The following sequence of steps is used.
[0101] (1) The Al.sub.2O.sub.3 support (1.0 gram) is calcined at
650.degree. C. for 1 hour. The support has a Brunauer-Emmett-Teller
(BET) surface area of 200 m.sup.2/g and a Barrett-Joyner-Halenda
(BJH) pore volume of 0.69 cm.sup.3/g.
[0102] (2) A first impregnation is conducted using 0.7 ml of
impregnation solution A to provide a total loading of 7.9% by
weight Co and 1.2% by weight Re.
[0103] (3) The catalyst is dried at 90.degree. C. for 12 hours, and
then calcined by increasing the temperature to 250.degree. C. at a
rate of 5.degree. C. per minute and then maintaining the
temperature at 250.degree. C. for 2 hours.
[0104] (4) The catalyst from step (3) has a BET surface area of 183
m.sup.2/g and a BJH pore volume of 0.57 cm.sup.3/g.
[0105] (5) A second impregnation is conducted using 0.57 ml of
impregnation solution B to provide a total loading of 13% by weight
Co and 2.0% by weight Re.
[0106] (6) The catalyst is dried at 90.degree. C. for 12 hours, and
then calcined by increasing the temperature to 250.degree. C. at a
rate of 5.degree. C. per minute and then maintaining the
temperature at 250.degree. C. for 2 hours.
[0107] (7) The catalyst from step (6) has a BET surface are of 162
m.sup.2/g, and a BJH pore volume of 0.48 cm.sup.3/g.
[0108] (8) A third impregnation is conducted using 0.48 ml of
impregnation solution C to provide a total loading of 19% by weight
Co and 2.9% by weight Re.
[0109] (9) The catalyst is dried at 90.degree. C. for 12 hours, and
then calcined by increasing the temperature to 250.degree. C. at a
rate of 5.degree. C. per minute and then maintaining the
temperature at 250.degree. C. for 2 hours.
[0110] (10) The catalyst from step (9) has a BET surface area of
144 m.sup.2/g and a BJH pore volume of 0.41 cm.sup.3/g.
[0111] (11) A fourth impregnation is conducted using 0.41 ml of
impregnation solution D with the result being a total loading of
25% by weight Co and 3.6% by weight Re.
[0112] (12) The catalyst is dried at 90.degree. C. for 12 hours,
and then calcined by increasing the temperature to 250.degree. C.
at a rate of 5.degree. C. per minute and then maintaining the
temperature at 250.degree. C. for 2 hours.
[0113] (13) A chemisorption test is conducted with the results
being 6.2% Co dispersion.
[0114] The pore volume and surface area data collected in the
above-indicated synthesis are disclosed in FIG. 10.
Example 2
[0115] A single batch of impregnation solution is used for the
following impregnations. The impregnation solution contains a
saturated solution of cobalt nitrate to which perrhenic acid is
added. The following procedure is used.
[0116] (1) The Al.sub.2O.sub.3 support (1 gram) is calcined at
650.degree. C. for 1 hour. The support has a BET surface area of
200 m.sup.2/g and a BJH pore volume of 0.69 cm.sup.3/g.
[0117] (2) A first impregnation is conducted using 0.69 ml of
impregnation solution to provide a total loading of 11.0% by weight
Co and 1.7% by weight Re.
[0118] (3) The catalyst is dried at 90.degree. C. for 12 hours, and
then calcined by increasing the temperature to 250.degree. C. at a
rate of 5.degree. C. per minute and then maintaining the
temperature at 250.degree. C. for 2 hours.
[0119] (4) The pore volume is assumed to be 0.52 cm.sup.3/g.
[0120] (5) A second impregnation is conducted using 0.66 ml of
impregnation solution to provide a total loading of 18% by weight
Co and 2.8% by weight Re.
[0121] (6) The catalyst is dried at 90.degree. C. for 12 hours, and
then calcined by increasing the temperature to 250.degree. C. at a
rate of 5.degree. C. per minute and then maintaining the
temperature at 250.degree. C. for 2 hours.
[0122] (7) The pore volume is assumed to be 0.435 cm.sup.3/g.
[0123] (8) A third impregnation is conducted using 0.63 ml of
impregnation solution to provide a total loading of 24% by weight
Co and 3.6% by weight Re.
[0124] (9) The catalyst is dried at 90.degree. C. for 12 hours, and
then calcined by increasing the temperature to 250.degree. C. at a
rate of 5.degree. C. per minute and then maintaining the
temperature at 250.degree. C. for 2 hours.
[0125] (10) The pore volume is assumed to be 0.39 cm.sup.3/g.
[0126] (11) A fourth impregnation is conducted using 0.61 ml of
impregnation solution with the result being a total loading of 28%
by weight Co and 4.2% by weight Re.
[0127] (12) The catalyst is dried at 90.degree. C. for 12 hours,
and then calcined by increasing the temperature to 250.degree. C.
at a rate of 5.degree. C. per minute and then maintaining the
temperature at 250.degree. C. for 2 hours.
[0128] (13) A chemisorption test indicates a 6.3% Co dispersion.
The catalyst has a BET surface area of 107 m.sup.2/g and a BJH pore
volume of 0.28 cm.sup.3/g.
[0129] Portions of the sample from the foregoing synthesis are used
to continue Co loading to 35% and 40% using the foregoing
method.
Example 3
[0130] A Fisher-Tropsch reaction is conducted in a microchannel
reactor. The microchannel reactor contains one process
microchannel. The process microchannel has a height of 0.51 mm, a
width of 0.7 cm, and a length of 5.1 cm. The process microchannel
contains 0.2 gram of a Co/Re catalyst which is supported on
Al.sub.2O.sub.3. The Co/Re molar ratio is 21. The catalyst is
prepared using a multi-impregnation method to achieve a 30% by
weight loading of Co, and a 4.5% by weight loading of Re. The metal
dispersion in the catalyst is 5.4%. The catalyst is in the form of
particulate solids having a particle size in the range of 177-250
microns. The solids are packed in the process microchannel. The
process microchannel is cooled with an adjacent heat exchanger to
the extent that the temperature gradient within the catalyst is
less than 5.degree. C.
[0131] The reactor is operated at 20 atmospheres with a GHSV of
12520 hr.sup.-1 which corresponds to 0.26 second contact time. At
224.degree. C. the CO conversion is 50% and the methane selectivity
is 10%. The pressure is increased to 35 atmospheres and the initial
CO conversion is increased to 65%, and the methane selectivity is
reduced to 6.8%. These results are shown in FIG. 14. Analysis of a
liquid/wax sample from the product indicates that the chain growth
probability is as high as 0.93.
[0132] The process is conducted at different operating pressures
ranging from 10 to 40 atmospheres, but at the same temperature
(225.degree. C.) and contact time (0.26 second). The results are
indicated in FIG. 15. The results indicate that the methane
selectivity is reduced from 12% to 6.5% when the system pressure
increases from 10 atmospheres to 40 atmospheres.
[0133] The process is conducted at 250.degree. C. with the results
being indicated in FIG. 16. Referring to FIG. 16, the process
achieves a CO conversion of 70% with the selectivity to methane
being 10%.
[0134] The process is repeated with the contact time being reduced
to 0.1 second (GHSV=33, 180 hr.sup.-1) at a pressure of 35
atmospheres and a temperature of 226.degree. C.
[0135] The results are indicated in FIG. 17 which shows a CO
conversion of 63% and a selectivity to methane of 10.5%.
Example 4
[0136] Two 30% Co-4.5% Re/Al.sub.2O.sub.3 catalysts are tested in a
Fischer-Tropsch synthesis reaction. One of the catalysts is made
using intercalcination steps. The other catalyst is made without
intercalcination steps. The catalyst made with the intercalcination
steps is made using the following procedure. The support is
impregnated with just enough saturated cobalt nitrate and perrhenic
acid in water solution to fill its pores. The impregnated support
is then heated at 90.degree. C. for 14 hours, then heated to
300.degree. C. at 5.degree. C./min and held at 300.degree. C. for
three hours for calcination before cooling to room temperature.
This procedure is repeated four times to achieve the desired Co and
Re loading.
[0137] The catalyst made without the intercalcination steps is made
using the following procedure. The support is impregnated with just
enough saturated cobalt nitrate and perrhenic acid in water
solution to fill its pores. The impregnated support is then heated
to 90.degree. C. and kept at 90.degree. C. for 14 hours before
cooling to room temperature. This procedure is repeated four times
to achieve the desired Co and Re loading. After the last
impregnation step the catalyst is heated to 350.degree. C. at a
rate of 10.degree. C. per minute and then held at 350.degree. C.
for three hours before being allowed to cool to room
temperature.
[0138] The Fischer-Tropsch reaction is conducted in a microchannel
reactor containing 5 process microchannels. The process
microchannels have the dimensions of 1.5 mm height, 0.635 cm width
and 2.54 cm length. Each process microchannel contains about 0.15
gram of catalyst. The catalyst has a particle size in the range of
150 to 250 microns. The process microchannels are cooled using an
adjacent heat exchanger. The reaction is conducted using a reactant
composition that contains 63.89 mol % hydrogen, 32.1 mol % carbon
monoxide and 4.01 mol % nitrogen. The inlet gage pressure 20.4
atmospheres. The reactor is operated isothermally at the
temperature indicated in FIG. 18. The weight hourly space velocity)
for carbon monoxide (mass of carbon monoxide fed per unit mass of
catalyst per hour) is 4.9. The results are indicated in FIG.
18.
[0139] While the invention has been explained in relation to
various detailed embodiments, it is to be understood that various
modifications thereof will become apparent to those skilled in the
art upon reading the specification. Therefore, it is to be
understood that the invention disclosed herein is intended to cover
such modifications as fall within the scope of the appended
claims.
* * * * *